A negative pressure pipeline material conveying control system and method

Abstract

The present application relates to material conveying control technical field, especially to a kind of negative pressure pipeline material conveying control system and method.The method includes the following steps: based on RS485 communication bus establishes heartbeat detection strategy between first end host and second end host;Through heartbeat detection strategy, the electromagnetic interference event of RS485 communication bus is continuously monitored to construct peak-avoiding adaptive transmission strategy;Through peak-avoiding adaptive transmission strategy, anti-interference time-sequenced interactive operation is executed, so as to realize negative pressure pipeline material conveying control.The present application executes anti-interference time-sequenced interactive operation through peak-avoiding adaptive transmission strategy, realizes the reliable communication and two-way linkage interlock of two end hosts, completely eliminates the secondary pushing and bump damage of sample to be measured in pipeline, so as to greatly improve the automation safety and the overall operation efficiency of detection process in the cross-laboratory circulation process of various samples to be measured.

Description

Technical Field

[0001] This invention relates to the field of material conveying control technology, and in particular to a negative pressure pipeline material conveying control system and method. Background Technology

[0002] Currently, negative pressure pipeline material conveying devices utilize negative pressure fans to generate airflow, driving the conveyor box to automatically transport materials between two workstations within a closed pipeline. Due to its advantages such as high conveying efficiency and high degree of automation, it has been widely used in factory workshops, workstation material turnover, and other application scenarios. In the sample testing process, the original sample often needs to be cut and disassembled into multiple standard test components, and then sorted according to category before being sent to different specialized laboratories for sub-item testing. The traditional model relies entirely on manual sorting and manual batch-by-batch transfer for testing, which consumes a lot of manpower and has low transfer efficiency. Therefore, the negative pressure pipeline conveying structure is introduced into the laboratory to realize the automatic turnover of samples between the cutting and sorting workstation and various specialized testing laboratories.

[0003] Existing conventional negative pressure conveying control schemes mostly rely on operators to visually determine the pipeline's idle status to start and stop the equipment, using a single mechanical limit switch for simple local interlocking. The controllers at both ends only coordinate their actions by sending and receiving simple commands via a standard RS485 communication bus. However, the operation of cutting equipment, frequency converters, and high-power electrical control devices within the laboratory generates high-intensity electromagnetic interference. The conveying pipelines across laboratories are usually long and have many areas with obstructed views. Under the high-frequency feeding conditions of continuous delivery of multiple types of samples, ordinary RS485 communication is highly susceptible to electromagnetic noise pulses, resulting in command packet loss and garbled messages. This causes the critical operating states such as material arrival lock-up and emergency stop anomalies at both ends to be out of real-time synchronization. In the case of state disconnection, the system cannot promptly identify the components to be tested remaining in the pipeline and lock the start-up permission. This leads to operators accidentally pressing the start button for secondary push when their view is obstructed, which in turn causes serious problems such as pipeline blockage and damage to the samples due to compression and impact. This makes it difficult to meet the requirements of continuous cross-laboratory conveying and highly reliable collaborative management of various samples after they have been split in the testing laboratory. Summary of the Invention

[0004] Based on this, the present invention provides a negative pressure pipeline material conveying control system and method to solve at least one of the above-mentioned technical problems.

[0005] To achieve the above objectives, a negative pressure pipeline material conveying control method is provided, applied to a negative pressure conveying device. The negative pressure conveying device includes a first-end host and a second-end host connected to a negative pressure conveying pipeline. Each host is equipped with a negative pressure fan, a material detection sensor, a main controller, and a start button. The two main controllers are interconnected via an RS485 communication bus. The negative pressure pipeline material conveying control method includes the following steps: Step S1: Establish a heartbeat detection strategy between the first host and the second host based on the RS485 communication bus; Step S2: Continuously monitor electromagnetic interference events on the RS485 communication bus using a heartbeat detection strategy to extract electromagnetic interference characteristic data; construct a peak avoidance adaptive transmission strategy based on the electromagnetic interference characteristic data; Step S3: In response to the start button being pressed, the communication session is locked and a transmission session identifier is generated; the first host and the second host perform anti-interference timed interaction operations through the peak avoidance adaptive transmission strategy and the transmission session identifier, thereby realizing synchronous and collaborative management of the operation permissions of both ends; Step S4: After the negative pressure material conveying is completed, cancel the conveying session identifier and unlock the communication session to realize the negative pressure pipeline material conveying control.

[0006] Preferably, the present invention also provides a negative pressure pipeline material conveying control system, which executes the negative pressure pipeline material conveying control method described above. The negative pressure pipeline material conveying control system includes: The heartbeat link maintenance module is used to establish a heartbeat detection strategy between the first-end host and the second-end host based on the RS485 communication bus. The peak-avoidance scheduling module is used to continuously monitor communication error events on the RS485 communication bus through a heartbeat detection strategy in order to extract electromagnetic interference characteristic data; and to construct a peak-avoidance adaptive transmission strategy based on the electromagnetic interference characteristic data. The session coordination control module is used to respond to the start button being pressed on the first host, triggering communication session locking and generating a transmission session identifier; the first host and the second host perform anti-interference timed interaction operations through peak avoidance adaptive transmission strategy and transmission session identifier, thereby realizing synchronous and coordinated management of operation permissions at both ends; The transmission session release module is used to release the transmission session identifier and unlock the communication session after detecting that the negative pressure material transmission is completed, so as to realize the control of negative pressure pipeline material transmission.

[0007] The beneficial effects of this invention are as follows: The aforementioned negative pressure pipeline material conveying control method establishes a heartbeat detection strategy between the first and second end hosts, and continuously monitors electromagnetic interference events on the RS485 communication bus to extract characteristic data such as the interference dominance period and phase prediction value. Based on this, a peak avoidance adaptive transmission strategy is constructed, and a command response retransmission mechanism is introduced. During communication interaction, the timing of electromagnetic noise pulses generated by laboratory cutting equipment and high-power electronic control devices is identified by interference period prediction. Non-urgent status synchronization packets and heartbeat packets are actively scheduled to be sent in the quiet interval of interference trough. At the same time, the determinism of the long-distance communication link across laboratories is maintained in real time by using heartbeat disconnection detection and retransmission logic. Compared to existing RS485 solutions that only achieve simple transparent character transmission and lack optimized transmission and reception timing and disconnection detection capabilities, this invention can effectively resist high-intensity electromagnetic interference in the laboratory, significantly reduce packet loss rate and probability of garbled logic, and ensure that critical operating states such as emergency stop triggering, position locking, and communication anomalies are kept consistent between the two host computers in real time. It eliminates operational conflicts caused by the fragmentation of control logic. When communication disconnection, fan timeout, or command anomaly occurs, this method can also trigger multi-scenario fully automatic linkage self-locking and audible and visual alarms, thereby greatly improving the system's operational stability and automation level in complex electromagnetic environments across rooms.

[0008] Furthermore, this method responds to the start button press by triggering a communication session lock and generating a unique delivery session identifier. This identifier enables synchronized and coordinated control of the operating permissions of both host machines. The identifier is deactivated and the lock is released upon task completion. When performing high-frequency continuous sample delivery tasks across laboratory blind spots and multiple sample types, the delivery session identifier is first used to ensure the logical uniqueness of the command and feedback sequence, effectively intercepting out-of-order messages not in the current session. Subsequently, a global session mechanism is used to lock the start permissions of both host machines in real time until the sample turnaround task is completed. Compared to existing technologies that heavily rely on manual visual confirmation or use single mechanical limit switches susceptible to environmental influences for local interlocking, this invention achieves remote linkage and interlocking across pipelines through a digital session mechanism. It can accurately identify the residual state of the tested component at the other end from the control logic level, completely eliminating blind repeated starts and secondary airflow pushes when samples are not removed. This is particularly suitable for the transmission and testing of materials such as leather, effectively avoiding pipeline blockage, sample compression and impact damage, and mechanical damage. Furthermore, this method relies entirely on pure control logic and communication protocol upgrades for functional iteration, requiring no complex mechanical modifications. Therefore, it boasts advantages such as strong structural versatility and convenient installation and modification, perfectly adapting to automated sorting and transfer operations in testing laboratories. While significantly reducing manual monitoring and batch-by-batch transfer costs, it comprehensively ensures highly reliable anti-misoperation control during the continuous cross-laboratory transport of various split samples. Attached Figure Description

[0009] Figure 1 This is a schematic diagram of the steps of the negative pressure pipeline material conveying control method of the present invention; Figure 2 This is a schematic diagram of the modules of the negative pressure pipeline material conveying control system of the present invention; Figure 3 This is an example diagram of the negative pressure pipeline material conveying device of the present invention; The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0010] The technical method of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0011] Furthermore, the accompanying drawings are merely illustrative of the invention and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and therefore repeated descriptions of them will be omitted. Some block diagrams shown in the drawings are functional entities and do not necessarily correspond to physically or logically independent entities. These functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor methods and / or microcontroller methods.

[0012] It should be understood that although the terms "first," "second," etc., may be used herein to describe various units, these units should not be limited by these terms. These terms are used merely to distinguish one unit from another. For example, without departing from the scope of the exemplary embodiments, a first unit may be referred to as a second unit, and similarly, a second unit may be referred to as a first unit. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0013] To achieve the above objectives, please refer to Figures 1 to 3 This invention provides a negative pressure pipeline material conveying control method, applied to a negative pressure conveying device. The negative pressure conveying device includes a first-end host and a second-end host connected to a negative pressure conveying pipeline. Each host is equipped with a negative pressure fan, a material detection sensor, a main controller, and a start button. The two main controllers are interconnected via an RS485 communication bus. The negative pressure pipeline material conveying control method includes the following steps: Step S1: Establish a heartbeat detection strategy between the first host and the second host based on the RS485 communication bus; Step S2: Continuously monitor electromagnetic interference events on the RS485 communication bus using a heartbeat detection strategy to extract electromagnetic interference characteristic data; construct a peak avoidance adaptive transmission strategy based on the electromagnetic interference characteristic data; Step S3: In response to the start button being pressed, the communication session is locked and a transmission session identifier is generated; the first host and the second host perform anti-interference timed interaction operations through the peak avoidance adaptive transmission strategy and the transmission session identifier, thereby realizing synchronous and collaborative management of the operation permissions of both ends; Step S4: After the negative pressure material conveying is completed, cancel the conveying session identifier and unlock the communication session to realize the negative pressure pipeline material conveying control.

[0014] The aforementioned negative pressure pipeline material conveying control method establishes a heartbeat detection strategy between the first and second end hosts, and continuously monitors electromagnetic interference events on the RS485 communication bus to extract characteristic data such as the interference dominance period and phase prediction value. Based on this, a peak avoidance adaptive transmission strategy is constructed, and a command response retransmission mechanism is introduced. During communication interaction, the timing of electromagnetic noise pulses generated by laboratory cutting equipment and high-power electronic control devices is identified by interference period prediction. Non-urgent status synchronization packets and heartbeat packets are actively scheduled to be sent in the quiet interval of interference trough. At the same time, the determinism of the long-distance communication link across laboratories is maintained in real time by using heartbeat disconnection detection and retransmission logic. Compared to existing RS485 solutions that only achieve simple transparent character transmission and lack optimized transmission and reception timing and disconnection detection capabilities, this invention can effectively resist high-intensity electromagnetic interference in the laboratory, significantly reduce packet loss rate and probability of garbled logic, ensure that critical operating states such as emergency stop triggering, position locking, and communication anomalies are kept consistent in real time between the two hosts, eliminate operational conflicts caused by control logic fragmentation, and trigger multi-scenario fully automatic linkage self-locking and audible and visual alarms when communication disconnection, fan timeout, or command anomaly occurs, thereby greatly improving the system's operational stability and automation level in complex electromagnetic environments across laboratories.

[0015] This invention is particularly suitable for the automated transmission and testing of flexible samples such as leather. Unlike rigid samples, which often exhibit brittle fracture upon impact within the pipeline, soft and lightweight materials like leather are easily subjected to continuous high-pressure compression at the pipeline end when encountering the blind secondary airflow of traditional systems. This can lead to irreversible and permanent physical deformations such as creases and curling on the sample surface. This invention relies on a highly rigorous cross-end authorization coordination and absolute locking mechanism to completely cut off the secondary airflow to the retained sample from the source. This mechanism not only eliminates the risk of pipeline blockage caused by the accumulation of flexible materials, but also maximizes the protection of the initial flatness and microstructural integrity of the leather sample. It fundamentally avoids the distortion of subsequent physical and mechanical property test data such as tensile strength and tear resistance caused by mechanical compression deformation during the transmission process. Thus, it provides a solid and non-destructive underlying transmission guarantee for the testing laboratory to issue high-precision and highly reliable leather test reports.

[0016] This invention provides a negative pressure pipeline material conveying device, including a negative pressure conveying pipeline, a material conveying box, and a first-end host and a second-end host located at the beginning and end of the pipeline, respectively. Both the first-end host and the second-end host are equipped with negative pressure fans connected to the pipeline ports. The generated airflow negative pressure pulls the material conveying box back and forth within the sealed negative pressure conveying pipeline. Each end host is externally equipped with a start button, a reset button, a self-locking emergency stop button, as well as running indicator lights, alarm indicator lights, material arrival indicator lights, and a buzzer for easy operation and status indication. Each end host is internally equipped with an infrared material detection sensor to detect in real time whether the material conveying box has arrived and stopped at its designated workstation. Furthermore, to address the strong electromagnetic environment of cutting equipment or high-power electrical control devices operating in the laboratory, the main controllers built into both end hosts use isolated RS485 modules for communication networking interconnection. This isolated RS485 module, in conjunction with terminating resistors at both ends of the bus, can effectively block ground loop common-mode interference generated by high-power devices, thereby significantly improving the physical layer anti-interference capability of long-distance communication links across laboratories.

[0017] Please see Figure 3This is an example diagram of the negative pressure pipeline material conveying device of the present invention. In this example, A in the diagram is a negative pressure conveying pipeline, which forms a negative pressure airflow passage inside. It relies on the negative pressure suction to pull the conveying box carrying the sample to move back and forth, realizing the automatic conveying of the cut and sorted test parts across laboratories; B is a local operation button panel, which integrates start, stop, reset, emergency stop buttons and running, fault, and position indicator lights, for on-site manual issuance of conveying instructions and viewing of equipment status; C is the main control controller box, which integrates the main control unit and isolated RS485 communication module to perform heartbeat monitoring of the two host units, anti-interference timing communication and overall conveying logic control; D is a material conveying box, which serves as a carrier for carrying the cut standard test parts. It is transferred across workstations along the negative pressure pipeline under the airflow traction of the negative pressure fan, replacing manual transfer and directly conveying the sorted samples to the corresponding dedicated testing laboratory, eliminating the manual transfer process.

[0018] In the embodiments of this invention, please refer to Figure 1 The above is a schematic flowchart of the negative pressure pipeline material conveying control method of the present invention. In this example, the negative pressure pipeline material conveying control method includes the following steps: Preferably, step S1: establish a heartbeat detection strategy between the first host and the second host based on the RS485 communication bus; Optionally, step S1 includes the following steps: Step S11: The first host and the second host periodically send heartbeat data packets to each other via RS485 communication bus. The heartbeat data packets carry the material occupancy status flag and emergency stop status data of the first host or the second host respectively. Step S12: The first or second host starts a timeout timer after each heartbeat data packet is sent; if no heartbeat data packet is received from the other end within the preset timeout threshold, the timeout timer is incremented by one. Step S13: When the accumulated value of the timeout timer reaches the preset communication disconnection judgment threshold, the RS485 communication bus is determined to be disconnected, and the communication abnormality emergency stop self-locking is immediately triggered, the running negative pressure fan is shut down, the operation permissions of the host at both ends are blocked in both directions, and the audible and visual alarms are triggered.

[0019] In one embodiment, to address the need for high-frequency, continuous, and automated turnover of multiple categories of standard test components between the cutting and sorting station and various specialized testing laboratories, the first-end host and the second-end host, according to system response requirements, are configured to exchange heartbeat data packets via an RS485 communication bus at a period of 500 milliseconds. The heartbeat data packet encapsulates a test component's occupancy status flag bit represented by 0 or 1 and emergency stop status data. After each transmission, the host immediately starts its built-in timeout timer. If no heartbeat data packet is received from the other end within the preset timeout threshold, the timeout error counter is incremented by one. The timeout threshold (e.g., 200 milliseconds) is pre-determined by statistically calculating the average of the transmission delay of the RS485 communication bus and the processing delay of the main controller, and then adding the maximum tolerance. When the cumulative value of the timeout error counter reaches the preset communication disconnection threshold (e.g., 3 times), this threshold is a limit value set in advance based on statistical testing of the normal occasional packet loss rate caused by the electromagnetic pulse generated by the operation of the cutting equipment in the laboratory, to tolerate such occasional packet loss. Once this limit value is reached, the system determines that the RS485 communication bus across the laboratory is disconnected. To prevent blind transport and crushing damage of samples across blind spots, the system immediately cuts off the pulse width modulation drive signal of the negative pressure fan to shut down the fan, and sets the start button to invalid at the software level, thereby bidirectionally locking the operation permissions of the main units at both ends of the cutting and sorting end and the detection receiving end. At the same time, the buzzer sounds and the alarm indicator flashes to trigger an audible and visual alarm.

[0020] Preferably, step S2: continuously monitor electromagnetic interference events on the RS485 communication bus using a heartbeat detection strategy to extract electromagnetic interference feature data; and construct a peak avoidance adaptive transmission strategy based on the electromagnetic interference feature data. Optionally, in step S2, the electromagnetic interference events of the RS485 communication bus are continuously monitored using a heartbeat detection strategy to extract electromagnetic interference feature data, including: Based on the heartbeat detection strategy, electromagnetic interference events of the RS485 communication bus are continuously monitored, and the timestamp and error type of each communication error are recorded to construct an error timestamp sequence. The error timestamp sequence is truncated using a preset sliding time window. The time interval between adjacent electromagnetic interference events within the window is counted, and the time interval with the highest frequency is taken as the interference dominance period. The duration of each electromagnetic interference event within a preset sliding time window is statistically analyzed, and the mean duration of the interference is calculated to obtain the average duration of the interference. An interference probability distribution model is constructed based on the interference dominance period and the average duration of interference. Based on the interference probability distribution model, the interference burst interval and silence interval are divided within each interference dominance period, and the current interference phase prediction value is calculated by combining the current position within the interference dominance period. The interference dominance period, the average duration of interference, and the current predicted interference phase are used as characteristic data of electromagnetic interference.

[0021] In one embodiment, the specific operation of continuously monitoring electromagnetic interference events on the RS485 communication bus is as follows: the main controller calls the interrupt service and cyclic redundancy check mechanism of the underlying serial port. When a data frame verification failure or abnormal bus level change is detected, an electromagnetic interference event is determined to have occurred. The system real-time clock is used to capture the current absolute time and associate it with the error code and store it in the cache to construct an error timestamp sequence. Then, a preset sliding time window is used to extract the most recent data in the sequence. The length of the sliding time window is set to, for example, 10 seconds. It is set in advance based on the typical operating cycle test calibration of the cutting and dismantling equipment and high-power sorting electronic control device in the laboratory. Then, the time difference between adjacent electromagnetic interference events within the window is calculated. The time difference with the highest frequency is found by frequency statistics as the interference dominance period. At the same time, the duration from each abnormal level change to bus recovery is measured and the arithmetic mean is calculated to obtain the average duration of the interference.

[0022] Based on this, a Gaussian-form interference probability distribution model is constructed according to the interference dominance period and the average duration of interference, and its mathematical expression is: ; In the formula Represents the phase of the time modulus The probability distribution of interference at the location, The phase obtained by subtracting the interference-dominant period from any timestamp. The phase of the interference burst center is obtained by averaging the historical error timestamps after removing the interference-dominant period. The time dispersion parameter is set to a value that is directly equal to half the average duration of the disturbance. For the natural constant The model uses an exponential function with base 0.5. Then, based on this model, the phase range with probability values ​​greater than a preset probability threshold (e.g., 0.5, set through extensive laboratory testing of electromagnetic noise samples in cross-regional pipeline environments) is divided into interference burst intervals, and the range less than or equal to this threshold is divided into silent intervals. The absolute time of the current system is modulo the interference dominance period, and the remainder is used directly as the predicted value of the current interference phase. Finally, the interference dominance period, the average duration of interference, and the predicted value of the current interference phase are extracted and merged as electromagnetic interference characteristic data characterizing the communication environment.

[0023] It should be noted that, considering the differences in electromagnetic environment distribution between the cutting and sorting station and various specialized testing laboratories due to spatial physical isolation, the host at both the cutting transmitter and the testing receiver independently maintains its own electromagnetic interference characteristic data. The host synchronizes the current interference phase prediction value of its own end to the other end through a heartbeat detection strategy. After receiving the data, the other end performs a weighted fusion with the current interference phase prediction value in its own electromagnetic interference characteristic data to dynamically maintain the electromagnetic interference characteristic data of both ends.

[0024] Optionally, the peak avoidance adaptive transmission strategy constructed based on electromagnetic interference characteristic data in step S2 includes: Based on the interference dominance period and average duration of interference in the electromagnetic interference characteristic data, the start time and end time of the silence window within each interference period are calculated to obtain the predicted silence window time period. The data to be sent by the first host and the second host are divided into two categories according to the sending priority: urgent data and non-urgent data. Among them, urgent data includes emergency stop instructions and fault alarm instructions, while non-urgent data includes heartbeat data packets and non-urgent status synchronization packets. For urgent data, immediately seize the RS485 communication bus for priority transmission; For non-urgent data, peak avoidance scheduling constraints are constructed. Based on the predicted quiet window period, the timing of non-urgent data transmission by each host is dynamically controlled to construct a peak avoidance adaptive transmission strategy.

[0025] In one embodiment, the specific operation of calculating the predicted quiet window time period based on electromagnetic interference characteristic data is as follows: add half of the average duration of interference to the interference burst center phase obtained above, and then add a pre-set safety protection margin on this basis. Use this calculation result as the start time of the quiet window. At the same time, subtract half of the average duration of interference and the above-mentioned safety protection margin from the interference burst center phase of the next cycle to obtain the end time of the quiet window. The time period between the two times is defined as the predicted quiet window time period in the electromagnetic interference trough. Here, the safety protection margin is set to 5 milliseconds, which is a compensation value obtained by calibrating after multiple statistical tests on the physical response delay fluctuation of the control system transceiver interface, taking into account the transmission delay caused by long-distance pipeline wiring across the laboratory and the glitch interference when the cutting and sorting station equipment starts and stops.

[0026] Specifically, when performing the task of sending out communication for cross-regional transfer of test samples, the data to be sent by the first host and the second host are distinguished and isolated according to the sending priority based on the instruction identification code encapsulated in the data packet header. Emergency stop instructions and fault alarm instructions that involve equipment operation safety and prevent the test components from rear-ending each other in closed pipelines are classified as emergency data, while heartbeat data packets used only to maintain communication status and regular workstation idle non-emergency state synchronization packets are classified as non-emergency data.

[0027] In one implementation of this embodiment, for emergency data, in order to ensure that the airflow of the fan can be blocked immediately in the event of a sudden anomaly to protect various standard test components from being squeezed and damaged, once the command trigger action is captured, other regular data scheduling queues that are currently being executed are immediately suspended, the transmit enable level of the communication control unit is forcibly pulled high, and the RS485 communication bus is directly preempted to complete the transmission operation of such commands first.

[0028] In one implementation of this embodiment, when constructing peak avoidance scheduling constraints for non-urgent data, the current absolute system time is extracted and periodically compared with the predicted silent window time period. If the current time falls within the time range of the silent window, the bus is directly activated to send the non-urgent data. If the current time is within the interference burst range of electromagnetic pulses, the non-urgent data is transferred to the internal delay buffer queue, and a hardware delay timer is configured and enabled to force the transmission of the data packet to be postponed until the start time of the nearest silent window arrives before the bus transmission is triggered. This achieves dynamic control over the timing of non-urgent data transmission between the two hosts, thereby constructing a peak avoidance adaptive transmission strategy that actively avoids strong electromagnetic noise in the laboratory. This ensures extremely high reliability of data interaction during the high-frequency continuous distribution of multiple types of samples across laboratories from the underlying link.

[0029] Most importantly, peak-avoidance scheduling constraints are constructed for non-urgent data. Using the predicted quiet window period as the scheduling benchmark, the timing of non-urgent data transmission from each host is dynamically controlled. Specifically: When non-urgent data is waiting to be sent, each host obtains the current interference phase prediction value in the electromagnetic interference characteristic data at the current moment and determines the type of interval to which the current moment belongs; If the current time is within the predicted silent window period, it is determined to be in a sendable state, and the send is executed immediately, recording the send time and the send result; If the current time is within the interference burst range, it is determined to be in the peak avoidance waiting state, the peak avoidance waiting timer is started, and the transmission time is delayed to the start time of the next predicted silent window; If the peak avoidance waiting timer exceeds the preset maximum waiting time limit and the predicted silent window start time has not been reached, the peak avoidance waiting state will be forcibly released, the transmission will be executed immediately, and this will be recorded as a timeout forced transmission. After each transmission is completed, the current interference phase prediction value is rolled over and corrected based on the transmission result. If the transmission is forced due to timeout and communication fails, the average duration of interference is increased by a preset duration compensation amount, and the silence start phase and predicted silence window time period are recalculated to update the electromagnetic interference characteristic data.

[0030] In one implementation of this embodiment, if it is determined that the current time is within the interference burst range of electromagnetic pulses, it is determined to be in a peak avoidance waiting state and the built-in peak avoidance waiting timer is started simultaneously. The non-urgent data to be sent is temporarily suspended and forcibly delayed until the start time of the next predicted silent window calculated on the time axis before triggering the sending action. During this waiting process, if the cumulative timing of the peak avoidance waiting timer exceeds the preset maximum waiting time limit and the start time of the predicted silent window has not been reached, the maximum waiting time limit is set to, for example, 50 milliseconds. This is a threshold obtained by pre-evaluating the maximum tolerable delay of the entire negative pressure transmission system for the non-urgent state synchronization signal and the extremely severe long pulse width noise interference of the high-power cutting and high-voltage detection equipment in the laboratory. Then, the current peak avoidance waiting state is forcibly released, the level of the sending pin is immediately pulled high to execute the data sending operation, and this action is clearly recorded as a timeout forced sending in the status log.

[0031] Preferably, in step S3: in response to the start button being pressed, a communication session lock is triggered and a transmission session identifier is generated; the first host and the second host perform anti-interference timing interaction operations through a peak avoidance adaptive transmission strategy and a transmission session identifier, thereby achieving synchronous and collaborative management of operation permissions at both ends; Optionally, in step S3, the first host and the second host perform anti-interference timing-based interaction operations through a peak-avoidance adaptive transmission strategy and by transmitting session identifiers, thereby achieving synchronized and collaborative management of operation permissions at both ends, including: When the first host detects that the local start button has been pressed, it controls the RS485 communication bus to enter a session lock state to suspend data interaction outside the current session. Extract local cached status data according to the heartbeat detection strategy or obtain the first status response message data returned by the second host by sending a status query command. Perform pre-start verification based on the first status response message data and obtain the delivery start command. The second-end host receives and parses the start command to perform a second status confirmation, drives the negative pressure fan to run and locks local permissions, or performs anomaly interception, and then generates a second status response message data and sends it back to the first-end host. The first host responds to the feedback status type carried in the second status response message data, and performs corresponding start permission locking processing or multi-level abnormal alarm guidance and troubleshooting control to achieve synchronous and coordinated management and control of operation permissions at both ends; Among them, the status query command, the first status response message data, the transmission start command and the second status response message data are all matched for legality and timing through the transmission session identifier, and the transmission timing is scheduled through the peak avoidance adaptive transmission strategy.

[0032] Specifically, the first host responds to the feedback status type carried in the second status response message data, and performs corresponding start-up permission locking processing or multi-level abnormal alarm guidance and troubleshooting control to achieve synchronous and coordinated management and control of operation permissions at both ends. When the first host receives the second status response message data, if the second status response message data is normal operating data of the wind turbine, the first host will simultaneously perform the start permission lock process to intercept the start button trigger signal during the transmission period. If the second status response message data is start-up anomaly diagnostic data, extract the anomaly classification code from the start-up anomaly diagnostic data, and drive the local audible and visual alarm module to issue the corresponding fault warning signal according to the anomaly classification code, so that the status query and start-up process can be re-executed after the fault is manually eliminated.

[0033] In one embodiment, for a scenario where an operator at the cutting and sorting station completes the packaging of a standard test component of a certain category and presses the start button to prepare for sending the sample to a designated specialized laboratory, the main controller of the first-end host, upon capturing the level transition signal of the local start button being pressed, immediately generates a globally unique digital code in its internal software register as a delivery session identifier. This establishes a dedicated control file for a single turnaround task of the current batch of samples. Simultaneously, it drives the RS485 communication bus into an exclusive session lock state, temporarily shielding and suspending all internal heartbeat detection and routine data interaction tasks that do not carry the delivery session identifier, thereby completely isolating logical crosstalk that may occur during the concurrent dispatch and scheduling of multiple categories of samples within the laboratory.

[0034] In one implementation of this embodiment, the first host will then prioritize calling the local memory cache area maintained based on the heartbeat detection strategy to extract the latest material status and emergency stop status of the target special testing laboratory receiving end. If the cached data is determined to be invalid due to exceeding the preset refresh validity period, a status query instruction with the aforementioned transport session identifier will be encapsulated according to a preset data frame format, and the instruction will be sent to the communication bus within the predicted quiet window period according to the aforementioned peak avoidance adaptive transmission strategy. After accurately receiving the first status response message data returned by the second host, the pre-start verification will be performed by extracting the status flag bit in the message. Once it is confirmed that the other end is not in an emergency stop state and the previous batch of samples to be tested has been safely removed by the testing personnel and the receiving and transmitting box has been completely emptied, a transport start instruction with a same-source transport session identifier will be compiled and generated in memory, thereby eliminating the possibility of different batches of samples colliding, confusing, or being crushed and damaged in the pipeline from the control source.

[0035] Specifically, after receiving the conveying start command, the main controller of the second-end host first verifies whether the conveying session identifier it carries matches and is valid, in order to intercept the incorrect delivery and receipt of samples caused by historical out-of-order commands that are delayed and retransmitted due to electromagnetic interference. After the verification is passed, it checks the real-time level status of the local infrared material detection sensor and the self-locking emergency stop button for secondary safety confirmation. If the secondary confirmation status is valid, the second-end host outputs a pulse width modulation signal to the underlying drive circuit to drive the negative pressure fan to operate, using the negative pressure airflow to smoothly pull the current batch of test components from the sorting station to this special laboratory, and sets the trigger response permission of the local start button to invalid in the software logic to lock the local operation permission; conversely, if the confirmation status is abnormal, the start process is directly intercepted at the underlying level to avoid damage to experimental equipment and safety accidents caused by forced feeding in blind spots. Subsequently, the fan execution result or the reason for abnormal blocking is encapsulated into second-state response message data, and continues to use the peak avoidance adaptive transmission strategy to send it back to the first-end host during the electromagnetic interference silence period.

[0036] Most importantly, after receiving the second status response message data containing the matching session identifier, the first-end host immediately extracts the encapsulated feedback status type code. If the feedback status indicates that the other end has started successfully, the main controller of the first-end host synchronously intercepts the subsequent physical trigger events of the start button at the local software level, thereby achieving synchronous locking of the start operation permissions of both ends until the material conveying task is completely completed. If the feedback status indicates that there is material stagnation or equipment emergency stop at the other end, the first-end host immediately calls the exception handling subroutine pre-stored in the motherboard flash memory chip, drives the buzzer to sound at a preset rapid frequency and outputs the corresponding fault type through different flashing frequencies of the alarm indicator light, thereby guiding the on-site operators to perform the corresponding level of troubleshooting, and thus achieving precise synchronization and collaborative control of the operation permissions of both ends under high-frequency material feeding conditions.

[0037] Optionally, based on the heartbeat detection strategy, local cached status data is extracted or a status query command is sent to obtain the first status response message data returned by the second-end host. Based on the first status response message data, pre-start verification is performed to obtain the transmission start command, including: The first host extracts local cache status data based on the heartbeat detection strategy. The local cache status data includes the material occupancy status flag and emergency stop status data of the second host. The local cached status data is judged to be valid. If the validity period is not valid, the first host generates a status query instruction containing a query operation code and a message sequence number. The status query command is sent to the second host using the RS485 communication bus to obtain the first status response message data returned by the second host. The first host verifies whether the second host is not occupied and has no emergency stop state based on the timely and qualified local cache status data or the first status response message data. If so, the first host releases the initial interception state of the start button, starts the local material detection sensor to monitor the filling status, and generates a first-end material ready mark; otherwise, the first host maintains the standby interception state. The first-end material ready identifier and the preset start operation code are encapsulated into a data packet according to the preset communication data frame protocol to generate a conveying start command carrying the first-end material ready identifier.

[0038] In one embodiment, the main controller of the first host extracts local cached status data containing the material occupancy status flag and emergency stop status data of the second host from the internal static memory based on a heartbeat detection strategy. It then subtracts the timestamp of the cached data from the absolute value of the current system clock to obtain the data residence time difference. This time difference is compared with a preset timeliness judgment threshold. If the time difference exceeds this threshold (e.g., 800 milliseconds, a tolerance limit pre-defined based on the average heartbeat transmission cycle plus the maximum network jitter delay calculated by the system), the local cached data is deemed unqualified for timeliness. A specific query opcode with an incrementing message sequence number is then generated in the internal control register, and these are concatenated to generate a status query instruction. This instruction is then sent to the second host via the RS485 communication bus, and the internal receive interrupt mechanism is simultaneously activated to capture the first status response message data returned by the second host based on this instruction.

[0039] In one implementation of this embodiment, the main controller of the first-end host parses and determines that the local cached status data is timely or the first status response message data is successfully received. It extracts the emergency stop logic bit and the material obstruction logic bit for comprehensive judgment to verify whether the second-end host is truly in a safe state of not occupying space and without emergency stop. If the verification result is yes, the initial interception flag of the local start button is set to zero in the underlying software logic to release the initial interception state, and a power-on enable signal is sent to the infrared material detection sensor built into the first-end host at the same time to start the sensor to perform real-time monitoring of the physical filling status of the local conveyor box. When a valid obstruction signal is received from the sensor, a first-end material ready flag is generated in the internal memory. Conversely, if the verification finds that there is material stagnation or an emergency stop lock-up condition at the other end, the first-end host maintains a standby interception state and ignores the physical trigger level of the start button from the underlying logic.

[0040] Specifically, after confirming that the loading at the first end is ready, the first end host calls the data packaging program to extract and aggregate the first end material ready identifier generated in memory and the start operation code pre-frozen in the system flash memory. It then strictly follows the preset communication data frame protocol, which includes a specific start frame header, data payload segment, and cyclic redundancy check tail, to perform bit-by-bit arrangement and byte concatenation operations, and finally encapsulates and generates a valid conveying start command carrying the first end material ready identifier.

[0041] Optionally, a status query command is sent to the second-end host using the RS485 communication bus to obtain the first status response message data returned by the second-end host, including: After receiving the status query command from the first host, the second host continuously collects the output level of the material detection sensor, detects the falling edge when the output level changes from high to low, and records the falling edge trigger time. Starting from the falling edge trigger moment, the output level is continuously sampled within the preset anti-jitter window, and the number of continuous sampling points that remain at a low level in the sampling results is counted. When the number of consecutive sampling points reaches the total number of sampling points within the preset anti-shake window, the detection is confirmed to be valid, and the second end placeholder flag is set to placeholder; if the number of consecutive sampling points does not reach the total number of sampling points, the current falling edge trigger time record is cleared, and the second end placeholder flag is set to unplaceholder. Read the relay contact level of the hardware circuit where the emergency stop button is located in the second-end host to determine the emergency stop status data of the second end; The second-end placeholder flag and the second-end emergency stop status data are mapped and spliced ​​according to the preset communication protocol format. The cyclic redundancy check code of the spliced ​​data is calculated. The spliced ​​data and the cyclic redundancy check code are appended to the standard frame header and frame tail, and encapsulated to form the first status response message data and sent back to the first-end host.

[0042] In one embodiment, after receiving a status query command from the first host, the second host continuously acquires the output level of the infrared material detection sensor through hardware signal pins. When the output level is detected to suddenly jump from a high level in an unobstructed state to a low level in an obstructed state, a valid falling edge is captured, and the internal real-time clock is immediately called to record the accurate trigger time of the falling edge. From the trigger time of the falling edge, the output level of the sensor is continuously sampled at a fixed high-frequency sampling rate within a preset anti-shake window, and an internal counter is started to count the number of continuous sampling points that remain in a low level state in the sampling results. The duration of the anti-shake window is, for example, set to 20 milliseconds, which is calibrated in advance by monitoring the mechanical vibration attenuation time generated when the conveyor box hits the buffer at the end of the pipe and extracting its maximum envelope value. The total number of sampling points planned in the anti-shake window is, for example, set to 10.

[0043] In one implementation of this embodiment, it is determined in real time whether the number of consecutive sampling points obtained by statistics reaches the total number of sampling points within the preset anti-shake window. When the two values ​​are equal, it is confirmed that the infrared blocking signal is stable and reliable, effectively eliminating false triggering caused by dust flying in the pipeline or brief vibration. Then, the second-end placeholder flag in the internal control word of the system is set to the logic high bit representing the occupied state. Conversely, if any high-level transition is detected within the anti-shake window, resulting in the number of consecutive low-level sampling points not reaching the total number of sampling points, it is determined that the falling edge signal is environmental noise interference. The falling edge trigger time record is directly cleared in memory, and the second-end placeholder flag is reset to the logic low bit representing the unoccupied state.

[0044] Optionally, the second-end host receives and parses the start command to perform a secondary status confirmation, drives the negative pressure fan to run and locks local access, or performs anomaly interception, thereby generating a second status response message and sending it back to the first-end host, including: After receiving the conveyor start command, the second-end host parses and extracts the material ready identifier from the first end, and simultaneously triggers the machine to confirm the emergency stop and the occupancy status, thus obtaining the secondary verification status data; among which, the secondary verification status data includes the safe waiting status and the start abnormal status. When the secondary verification status data is in a safe and ready-to-receive state, the second-end host responds to the material ready flag, drives the corresponding negative pressure fan of the second-end host to run, and simultaneously locks the start permission of the second-end host to generate normal fan operation data; When the secondary verification status data indicates an abnormal startup status, the second-end host intercepts the drive signal of the negative pressure fan, keeping it in a stopped state, and generates startup abnormality diagnostic data containing an abnormality classification code. Encapsulate the abnormal startup diagnostic data or the normal operation data of the wind turbine into a second-state response message.

[0045] In one implementation of this embodiment, after the main controller of the second-end host receives the conveying start command through the serial communication bus, it parses and extracts the first-end material ready identifier from the payload segment according to the preset data frame protocol. At the same time, it immediately triggers the secondary polling mechanism of the local hardware input / output interface to read the real-time output signal of the infrared material detection sensor and the physical level status of the self-locking emergency stop button again. Based on this, it performs a comprehensive logical judgment to obtain secondary verification status data. In the system logic, the secondary verification status data is divided into a safe waiting state representing no occupation and no emergency stop at this end, and a start-up abnormal state representing material stagnation or the emergency stop button being pressed.

[0046] In one implementation of this embodiment, when the secondary verification status data is determined to be in a safe waiting state, the system immediately responds to the first-end material ready flag, outputs a pulse width modulation signal to the underlying motor drive circuit to drive the negative pressure fan corresponding to the second-end host to generate traction airflow negative pressure. At the same time, the trigger flag bit of the local start button is forcibly set to zero in the internal control program, thereby synchronously locking the start permission of the second-end host, and generating corresponding fan normal operation data in the memory register. When the secondary verification status data is determined to be in a start abnormal state, the system intercepts and cuts off the pulse width modulation signal output to the motor drive circuit, forcibly keeping the negative pressure fan in a stopped state to avoid pipeline compression accidents, and generates start abnormal diagnostic data containing abnormal classification codes according to the specific trigger source. For example, the classification code for the occupancy abnormality caused by the failure to remove the material at the other end is set to 01, and the classification code for the emergency stop abnormality caused by button triggering is set to 02.

[0047] Preferably, step S4: after the negative pressure material conveying is completed, the conveying session identifier is cancelled and the communication session lock status is released to realize the negative pressure pipeline material conveying control.

[0048] In one embodiment, when the conveyor box in the negative pressure pipeline reaches the destination station and the internal material is removed by the operator, the infrared material detection sensor built into the host unit at this end returns to an unobstructed high-level state. After confirming that the state is stable, it determines that the material conveying task is completed, and then sends an unlock and reset command carrying the current conveying session identifier to the initiating host through the communication bus. After receiving and verifying that the conveying session identifier is valid, the initiating host immediately clears the data bit corresponding to the identifier in its internal memory to perform a deregistration action, and simultaneously cancels the bus exclusive control word at the software level to unlock the communication session lock state, so that the communication bus fully resumes the periodic interaction of normal heartbeat data packets and non-urgent data, thereby allowing the entire conveying device to smoothly return to the initial standby ready state that allows the response to the next start task, thus realizing complete negative pressure pipeline material conveying control.

[0049] Optionally, during the operation of the negative pressure fan, the following may also be included: Obtain the reference current curve during the normal operation of the negative pressure fan. The reference current curve is divided into three segments according to the delivery cycle time axis: the start-up acceleration segment, the stable cruise segment, and the arrival deceleration segment. Each segment includes the corresponding expected value of the reference current. During the operation of the negative pressure fan, the real-time current value of the negative pressure fan drive circuit is continuously collected at a preset sampling frequency. The real-time current sampling sequence is constructed according to the sampling timestamp order, and each sampling point is assigned to the corresponding segment interval according to the running time of the current transmission cycle to obtain segmented real-time current data. For each segmented interval in the segmented real-time current data, the current characteristic analysis is performed with the expected value of the corresponding segmented reference current in the reference current curve to obtain the current segmented characteristic parameter set. Based on the current segmentation characteristic parameter set, the jamming risk index, leakage risk index and local resistance anomaly index are calculated respectively. The blockage risk index, leakage risk index, and local resistance anomaly index are fused and scored according to preset comprehensive weights to generate a comprehensive pipeline health score. Based on the blockage risk index, leakage risk index, local resistance anomaly index, and pipeline comprehensive health score, the current status of the negative pressure transmission pipeline is determined as a blockage fault, leakage fault, local resistance anomaly, or healthy state, and encapsulated as a pipeline health diagnosis message to trigger the corresponding abnormal alarm.

[0050] In one embodiment, during the no-load trial operation phase after the initial installation or standard maintenance of the equipment, the negative pressure fan is started and the stable current change trajectory within the complete material conveying cycle is recorded to obtain the reference current curve. For example, based on the motion physical characteristics of the conveyor box, the conveying cycle time axis is divided into three segments: a starting acceleration segment of 0 to 1.5 seconds, a stable cruise segment of 1.5 to 8.5 seconds, and a deceleration segment of 8.5 to 10 seconds. The time nodes of each segment are pre-defined by statistically analyzing the average time taken for a standard mass conveyor box to pass through each characteristic position of the pipeline under rated negative pressure, and the average current data within each segment time in the above standard test is extracted as the corresponding reference current expectation value.

[0051] In one implementation of this embodiment, during the actual operation of the negative pressure fan to perform material transfer tasks, the real-time current value of the negative pressure fan drive circuit is continuously collected at a preset sampling frequency (e.g., set to 100 Hz, to balance capturing high-frequency abnormal current fluctuations and saving internal storage space) through the built-in current transformer and analog-to-digital conversion circuit. The real-time current sampling sequence is constructed in memory according to the absolute sampling timestamp sequence assigned by the hardware clock. Then, the time axis nodes are compared with the running time after the fan start command is issued, and each sampling point in the sequence is assigned to the aforementioned start-up acceleration segment, stable cruise segment, or arrival deceleration segment, thereby extracting segmented real-time current data.

[0052] The calculated blockage risk index, leakage risk index, and local resistance anomaly index are weighted and summed according to preset comprehensive weights (e.g., 0.5, 0.3, and 0.2, respectively, which are pre-determined based on the severity of each fault leading to downtime accidents in actual production). This multi-dimensional feature fusion scoring is then used to generate a comprehensive pipeline health score. Finally, the three individual indices are compared with preset individual fault judgment thresholds, and the comprehensive pipeline health score is verified against a preset health benchmark score. If any individual index exceeds the limit, the current state of the negative pressure conveying pipeline is directly determined to be a blockage fault, leakage fault, or local resistance anomaly. If all individual indices do not exceed the limit and the comprehensive health score meets the standard, it is determined to be in a healthy state. Finally, the judgment result, along with the underlying feature indices, is encapsulated into a standard format pipeline health diagnosis message and sent along the communication bus so that a local audible and visual alarm can be triggered immediately when a fault is diagnosed, guiding manual and accurate troubleshooting.

[0053] Most importantly, for each segment of the segmented real-time current data, current characteristic analysis is performed on the corresponding segment's expected reference current value in the reference current curve to obtain the current segment characteristic parameter set, including: For the startup acceleration phase, extract the peak current and peak arrival time from the real-time current sampling sequence, calculate the deviation between the peak current and the expected value of the reference current corresponding to the startup acceleration phase in the reference current curve, and record it as the startup peak deviation; calculate the time difference between the peak arrival time and the preset standard peak time, and record it as the startup timing deviation. For the stable cruise segment, the mean and standard deviation of all sampling points within the stable cruise segment are calculated to obtain the mean of the measured current in the cruise segment and the standard deviation of the current fluctuation in the cruise segment; the difference between the mean of the measured current in the cruise segment and the expected value of the reference current corresponding to the stable cruise segment in the reference current curve is calculated and denoted as the cruise mean deviation. For the deceleration section at the point of arrival, linear regression fitting is performed on the sampling points within the deceleration section to extract the current drop slope. The ratio of the current drop slope to the preset standard drop slope is calculated and denoted as the deceleration slope ratio. By integrating the peak deviation at startup, the timing deviation at startup, the mean deviation of cruise, the standard deviation of current fluctuation during cruise, and the deceleration slope ratio, a set of current segment characteristic parameters for this transmission cycle is obtained.

[0054] In one embodiment, the specific operation for extracting the current characteristics of the startup acceleration segment is as follows: traverse all sampling points in the real-time current data of the segment, compare and extract the sampling point with the largest value as the current peak value, and record the hardware absolute timestamp corresponding to the point as the peak arrival time. Then, subtract the reference current expectation value corresponding to the startup acceleration segment in the reference current curve from the current peak value (the reference current expectation value is set to, for example, 5.0 amperes, which is obtained in advance by averaging the transient current peak value when the wind turbine starts under normal no-load conditions). The difference is recorded as the startup peak deviation. At the same time, subtract the preset standard peak time from the peak arrival time (the preset standard peak time is set to, for example, 0.8 seconds after the wind turbine receives the start command, which is a reference time set in advance based on the prior data of the motor's startup mechanical characteristics). The resulting time difference is recorded as the startup timing deviation.

[0055] In one implementation of this embodiment, when extracting current characteristics for the stable cruise segment, all sampling point data within the stable cruise segment are substituted into a built-in statistical algorithm model for calculation to obtain the mean measured current of the cruise segment and the standard deviation of the current fluctuation in the cruise segment. The formula for calculating the mean is as follows: The formula for calculating the standard deviation is: In the formula This represents the calculated average measured current during the cruise segment. This represents the calculated standard deviation of the cruise current fluctuation. This indicates the total number of sampling points collected during the stable cruise segment. Indicates the first The real-time current data collected at each sampling point is then used to calculate the average measured current of the cruise segment. The mean value of the reference current corresponding to the stable cruise segment in the reference current curve is then subtracted from the mean value of the measured current of the cruise segment (the mean value of the reference current is set to, for example, 3.2 amperes, which is obtained in advance through the reference load current calibration extracted by the standard stable delivery test). The difference obtained directly is recorded as the cruise mean deviation.

[0056] Specifically, the current feature extraction operation for the deceleration section is as follows: the least squares algorithm is called to perform a linear regression fitting operation on the current values ​​and timestamp coordinates of all sampling points in the segment, and the first derivative of the fitted straight line equation is extracted as the current descent slope. Then, the current descent slope is divided by a preset standard descent slope (the preset standard descent slope is set to, for example, -1.5 amperes per second, which is a fixed slope constant calibrated by actual measurement using the damping characteristics of the rotor naturally decelerating under the standard back pressure of the pipeline after the fan is powered off). The quotient is recorded as the deceleration slope ratio. The starting peak deviation, starting timing deviation, cruise mean deviation, cruise current fluctuation standard deviation, and deceleration slope ratio obtained by the above calculation are spliced ​​and integrated one by one to obtain a set of current segment feature parameters covering the dynamic physical changes of the entire transmission cycle.

[0057] Most importantly, the jamming risk index, leakage risk index, and local resistance anomaly index are calculated based on the current segmentation characteristic parameter set, as follows: The cruise deviation rate is obtained by dividing the cruise mean deviation by the expected value of the reference current corresponding to the stable cruise segment in the reference current curve; the fluctuation coefficient is obtained by dividing the standard deviation of the cruise segment current fluctuation by the mean value of the measured current in the cruise segment; the cruise deviation rate and the fluctuation coefficient are weighted and summed according to the preset jamming weighting coefficient to obtain the jamming risk index. Extract the duration for which the current value in continuous sampling points within the stable cruise segment is lower than the lower limit of the tolerance band corresponding to the reference current curve. Define the ratio of the duration to the total duration of the stable cruise segment as the low current ratio. Weight the low current ratio and the absolute value of the starting peak deviation according to the preset leakage weighting coefficient to obtain the leakage risk index. Fast Fourier Transform is performed on the real-time current sampling sequence of the stable cruise segment in the segmented real-time current data to extract the top three frequency components with the largest amplitude in the spectrum and their corresponding amplitudes; the ratio of the sum of the amplitudes of the three frequency components to the mean of the measured current in the cruise segment is calculated and denoted as the high-frequency energy ratio; the deviation of the high-frequency energy ratio from the deceleration slope ratio is weighted and summed according to the preset resistance weighting coefficient to obtain the local resistance anomaly index.

[0058] In one embodiment, the specific operation of calculating the jamming risk index based on the current segment feature parameter set is as follows: extract the cruise mean deviation obtained in the previous step, divide it by the expected value of the reference current corresponding to the stable cruise segment in the reference current curve to obtain the cruise deviation rate, and at the same time divide the standard deviation of the cruise segment current fluctuation by the mean of the measured current in the cruise segment to calculate the fluctuation coefficient. Then, call the built-in linear weighted algorithm model, and perform a weighted summation of the cruise deviation rate and the fluctuation coefficient according to the preset jamming weighting coefficient. The mathematical calculation formula is as follows: ; In the formula, This represents the calculated congestion risk index. Indicates the deviation of the cruise mean. This represents the expected reference current value corresponding to the stable cruise phase. This represents the standard deviation of the current fluctuation during the cruise phase. This represents the average measured current during the cruise phase. and These represent the preset jamming weighting coefficients corresponding to the cruise deviation rate and the fluctuation coefficient, respectively. Their values ​​are set to, for example, 0.65 and 0.35, respectively. These weighting ratios are obtained in advance by performing multiple regression analysis on the current characteristic data of historical pipeline foreign object jamming failure samples. The result after calculation is used as the final jamming risk index.

[0059] In one implementation of this embodiment, when calculating the leakage risk index, a lower limit of the tolerance band is set based on the expected value of the reference current (for example, taking 90% of the expected value of the reference current as the lower limit to reserve margin for normal aerodynamic fluctuations). Then, the sampled data within the stable cruise segment is traversed to extract the duration for which the continuous current value is lower than the lower limit of the tolerance band, and the calculation formula is used. Perform the calculation, where Indicates the leakage risk index. This indicates the duration of time the data shows the error is below the lower limit of the tolerance band, as calculated statistically. This indicates the total duration of the stable cruise segment (e.g., fixed at 7.0 seconds). Indicates the peak deviation at startup. This indicates the operation of taking the absolute value of it. and These represent the preset leakage weighting coefficients corresponding to the low current ratio and the absolute value of the peak deviation, respectively. Their values ​​are set to, for example, 0.7 and 0.3, respectively. These are sensitivity coefficients determined in advance by combining fluid dynamics simulation and empirical seal failure test data. After substituting the relevant extracted values ​​into the above formula and weighting and summing them, the leakage risk index is obtained.

[0060] Specifically, the operation for calculating the local drag anomaly index involves calling the underlying digital signal processing library to perform a Fast Fourier Transform on the real-time current sampling sequence of the stable cruise segment in the segmented real-time current data, converting the time-domain current signal into a frequency-domain signal. The operation then extracts the three frequency components with the largest amplitudes and their corresponding amplitude values ​​by traversing the spectral sequence, and subsequently calculates them according to the mathematical formula. Solve for the local resistance anomaly index, where This represents the calculated local resistance anomaly index. , , These represent the amplitude values ​​of the extracted first, second, and third order high-frequency components, respectively. This represents the average measured current during the aforementioned cruise segment. Indicates the deceleration slope ratio. This represents the absolute value of the deviation of the deceleration slope from the ideal value of 1. and These represent the preset resistance weighting coefficients, with values ​​set to, for example, 0.55 and 0.45 respectively. These are the characteristic importance distribution ratios calculated in advance using perturbation experiments of the friction coefficient of the inner wall of the pipeline. The result obtained after completing the calculation is used as the local resistance anomaly index characterizing the abnormal state of pipeline resistance.

[0061] Specifically, the sampling time corresponding to the first time the blockage risk index in the real-time current sampling sequence exceeds the preset blockage judgment threshold is extracted. The time difference between the sampling time and the current negative pressure fan start time is calculated and recorded as the blockage abnormality time offset. The historical average total consumption time of normal operation is read, and the blockage abnormality time offset is divided by the historical average total consumption time of normal operation to obtain the fault time ratio. The fault time ratio is multiplied by the preset total length of the negative pressure conveying pipeline to obtain the estimated distance of the fault location. The estimated distance of the fault location and the current conveying direction mark are encapsulated together and written into the fault diagnosis report and transmitted to the visualization terminal device.

[0062] Specifically, when either end host detects that the emergency stop button has been pressed, that end host immediately cuts off the power output of the negative pressure fan, locks the operating authority of the unit, and skips the normal communication sequence, prioritizing the issuance of an emergency stop linkage command to the other end host via the RS485 communication bus. Upon receiving the command, the other end host synchronously executes the shutdown and authority lock. In the locked state, when the reset button of either end host is triggered, the triggering end host clears the local lockout and fault flags and generates a reset command to send to the other end host. Both ends host synchronously clear the abnormal status flags and restore the start button's valid authority.

[0063] In one implementation of this embodiment, the negative pressure pipeline material conveying control system is mainly deployed in the main controllers of the first and second end hosts of the negative pressure conveying device. Specifically, it can be manifested as a logic control module running on an embedded main control board, a programmable logic controller (PLC), or an industrial microprocessor. In practical application scenarios, the system interconnects the two hosts through a serial communication bus. By utilizing the computing and I / O scheduling capabilities of the main controller, it achieves real-time control of infrared sensor signal acquisition, negative pressure fan speed regulation drive, and human-machine interface panel. This system can also be applied to various general or special industrial material turnover environments, such as production line material flow and warehouse automatic delivery system configurations. Through the distributed logic collaboration of the two main control units, it achieves bidirectional interlocking and highly reliable conveying control of material arrival in complex working conditions such as factory workshops and warehouse logistics.

[0064] Please see Figure 2Preferably, the present invention also provides a negative pressure pipeline material conveying control system 100, which executes the negative pressure pipeline material conveying control method described above. The negative pressure pipeline material conveying control system includes: Heartbeat link maintenance module 101 is used to establish a heartbeat detection strategy between the first host and the second host based on the RS485 communication bus. The peak-avoidance scheduling module 102 is used to continuously monitor communication error events of the RS485 communication bus through a heartbeat detection strategy in order to extract electromagnetic interference characteristic data; and to construct a peak-avoidance adaptive transmission strategy based on the electromagnetic interference characteristic data. The session coordination control module 103 is used to respond to the start button of the first host, trigger the communication session lock and generate a transmission session identifier; the first host and the second host perform anti-interference timed interaction operations through peak avoidance adaptive transmission strategy and transmission session identifier, thereby realizing synchronous and coordinated management of operation permissions at both ends; The transmission session release module 104 is used to release the transmission session identifier and unlock the communication session after detecting that the negative pressure material transmission is completed, so as to realize the control of negative pressure pipeline material transmission.

[0065] Therefore, the embodiments should be considered as exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of the equivalents of the application are intended to be included within the invention.

[0066] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features of the invention herein.

Claims

1. A method for controlling material conveying in a negative pressure pipeline, characterized in that, This method is applied to a negative pressure conveying device, which includes a first-end host and a second-end host connected to a negative pressure conveying pipeline. Each host is equipped with a negative pressure fan, a material detection sensor, a main controller, and a start button. The two main controllers are interconnected via an RS485 communication bus. The negative pressure pipeline material conveying control method includes the following steps: Step S1: Establish a heartbeat detection strategy between the first host and the second host based on the RS485 communication bus; Step S2: Continuously monitor electromagnetic interference events on the RS485 communication bus using a heartbeat detection strategy to extract electromagnetic interference characteristic data; construct a peak avoidance adaptive transmission strategy based on the electromagnetic interference characteristic data; Step S3: In response to the start button being pressed, the communication session is locked and a transmission session identifier is generated; the first host and the second host perform anti-interference timed interaction operations through the peak avoidance adaptive transmission strategy and the transmission session identifier, thereby realizing synchronous and collaborative management of the operation permissions of both ends; Step S4: After the negative pressure material conveying is completed, cancel the conveying session identifier and unlock the communication session to realize the negative pressure pipeline material conveying control.

2. The negative pressure pipeline material conveying control method according to claim 1, characterized in that, Step S1 includes the following steps: Step S11: The first host and the second host periodically send heartbeat data packets to each other via RS485 communication bus. The heartbeat data packets carry the material occupancy status flag and emergency stop status data of the first host or the second host respectively. Step S12: The first or second host starts a timeout timer after each heartbeat data packet is sent; if no heartbeat data packet is received from the other end within the preset timeout threshold, the timeout timer is incremented by one. Step S13: When the accumulated value of the timeout timer reaches the preset communication disconnection judgment threshold, the RS485 communication bus is determined to be disconnected, and the communication abnormality emergency stop self-locking is immediately triggered, the running negative pressure fan is shut down, the operation permissions of the host at both ends are blocked in both directions, and the audible and visual alarms are triggered.

3. The negative pressure pipeline material conveying control method according to claim 1, characterized in that, In step S2, an electromagnetic interference event on the RS485 communication bus is continuously monitored using a heartbeat detection strategy to extract electromagnetic interference characteristic data, including: Based on the heartbeat detection strategy, electromagnetic interference events of the RS485 communication bus are continuously monitored, and the timestamp and error type of each communication error are recorded to construct an error timestamp sequence. The error timestamp sequence is truncated using a preset sliding time window. The time interval between adjacent electromagnetic interference events within the window is counted, and the time interval with the highest frequency is taken as the interference dominance period. The duration of each electromagnetic interference event within a preset sliding time window is statistically analyzed, and the mean duration of the interference is calculated to obtain the average duration of the interference. An interference probability distribution model is constructed based on the interference dominance period and the average duration of interference. Based on the interference probability distribution model, the interference burst interval and silence interval are divided within each interference dominance period, and the current interference phase prediction value is calculated by combining the current position within the interference dominance period. The interference dominance period, the average duration of interference, and the current predicted interference phase are used as characteristic data of electromagnetic interference.

4. The negative pressure pipeline material conveying control method according to claim 3, characterized in that, Step S2, which involves constructing a peak-avoidance adaptive transmission strategy based on electromagnetic interference characteristic data, includes: Based on the interference dominance period and average duration of interference in the electromagnetic interference characteristic data, the start time and end time of the silence window within each interference period are calculated to obtain the predicted silence window time period. The data to be sent by the first host and the second host are divided into two categories according to the sending priority: urgent data and non-urgent data. Among them, urgent data includes emergency stop instructions and fault alarm instructions, while non-urgent data includes heartbeat data packets and non-urgent status synchronization packets. For urgent data, immediately seize the RS485 communication bus for priority transmission; For non-urgent data, peak avoidance scheduling constraints are constructed. Based on the predicted quiet window period, the timing of non-urgent data transmission by each host is dynamically controlled to construct a peak avoidance adaptive transmission strategy.

5. The negative pressure pipeline material conveying control method according to claim 1, characterized in that, In step S3, the first host and the second host perform anti-interference timing-based interaction operations through peak-avoidance adaptive transmission strategies and transmission session identifiers, thereby achieving synchronous and collaborative management of operation permissions at both ends, including: When the first host detects that the local start button has been pressed, it controls the RS485 communication bus to enter a session lock state to suspend data interaction outside the current session. Extract local cached status data according to the heartbeat detection strategy or obtain the first status response message data returned by the second host by sending a status query command. Perform pre-start verification based on the first status response message data and obtain the delivery start command. The second-end host receives and parses the start command to perform a second status confirmation, drives the negative pressure fan to run and locks local permissions, or performs anomaly interception, and then generates a second status response message data and sends it back to the first-end host. The first host responds to the feedback status type carried in the second status response message data, and performs corresponding start permission locking processing or multi-level abnormal alarm guidance and troubleshooting control to achieve synchronous and coordinated management and control of operation permissions at both ends; Among them, the status query command, the first status response message data, the transmission start command and the second status response message data are all matched for legality and timing through the transmission session identifier, and the transmission timing is scheduled through the peak avoidance adaptive transmission strategy.

6. The negative pressure pipeline material conveying control method according to claim 5, characterized in that, Based on the heartbeat detection strategy, local cached status data is extracted or a status query command is sent to obtain the first status response message data returned by the second-end host. Based on the first status response message data, pre-start verification is performed to obtain the transmission start command, including: The first host extracts local cache status data based on the heartbeat detection strategy. The local cache status data includes the material occupancy status flag and emergency stop status data of the second host. The local cached status data is judged to be valid. If the validity period is not valid, the first host generates a status query instruction containing a query operation code and a message sequence number. The status query command is sent to the second host using the RS485 communication bus to obtain the first status response message data returned by the second host. The first host verifies whether the second host is not occupied and has no emergency stop state based on the timely and qualified local cache status data or the first status response message data. If so, the first host releases the initial interception state of the start button, starts the local material detection sensor to monitor the filling status, and generates a first-end material ready mark; otherwise, the first host maintains the standby interception state. The first-end material ready identifier and the preset start operation code are encapsulated into a data packet according to the preset communication data frame protocol to generate a conveying start command carrying the first-end material ready identifier.

7. The negative pressure pipeline material conveying control method according to claim 6, characterized in that, Using the RS485 communication bus, a status query command is sent to the second-end host to obtain the first status response message data returned by the second-end host, including: After receiving the status query command from the first host, the second host continuously collects the output level of the material detection sensor, detects the falling edge when the output level changes from high to low, and records the falling edge trigger time. Starting from the falling edge trigger moment, the output level is continuously sampled within the preset anti-jitter window, and the number of continuous sampling points that remain at a low level in the sampling results is counted. When the number of consecutive sampling points reaches the total number of sampling points within the preset anti-shake window, the detection is confirmed to be valid, and the second end placeholder flag is set to placeholder; if the number of consecutive sampling points does not reach the total number of sampling points, the current falling edge trigger time record is cleared, and the second end placeholder flag is set to unplaceholder. Read the relay contact level of the hardware circuit where the emergency stop button is located in the second-end host to determine the emergency stop status data of the second end; The second-end placeholder flag and the second-end emergency stop status data are mapped and spliced ​​according to the preset communication protocol format. The cyclic redundancy check code of the spliced ​​data is calculated. The spliced ​​data and the cyclic redundancy check code are appended to the standard frame header and frame tail, and encapsulated to form the first status response message data and sent back to the first-end host.

8. The negative pressure pipeline material conveying control method according to claim 5, characterized in that, The second-end host receives and parses the start command to perform a second status confirmation, drives the negative pressure fan to run and locks local access, or performs anomaly interception, thereby generating a second status response message and sending it back to the first-end host, including: After receiving the conveyor start command, the second-end host parses and extracts the material ready identifier from the first end, and simultaneously triggers the machine to confirm the emergency stop and the occupancy status, thus obtaining the secondary verification status data; among which, the secondary verification status data includes the safe waiting status and the start abnormal status. When the secondary verification status data is in a safe and ready-to-receive state, the second-end host responds to the material ready flag, drives the corresponding negative pressure fan of the second-end host to run, and simultaneously locks the start permission of the second-end host to generate normal fan operation data; When the secondary verification status data indicates an abnormal startup status, the second-end host intercepts the drive signal of the negative pressure fan, keeping it in a stopped state, and generates startup abnormality diagnostic data containing an abnormality classification code. Encapsulate the abnormal startup diagnostic data or the normal operation data of the wind turbine into a second-state response message.

9. The negative pressure pipeline material conveying control method according to claim 8, characterized in that, During the operation of the negative pressure fan, the following are also included: Obtain the reference current curve during the normal operation of the negative pressure fan. The reference current curve is divided into three segments according to the delivery cycle time axis: the start-up acceleration segment, the stable cruise segment, and the arrival deceleration segment. Each segment includes the corresponding expected value of the reference current. During the operation of the negative pressure fan, the real-time current value of the negative pressure fan drive circuit is continuously collected at a preset sampling frequency. The real-time current sampling sequence is constructed according to the sampling timestamp order, and each sampling point is assigned to the corresponding segment interval according to the running time of the current transmission cycle to obtain segmented real-time current data. For each segmented interval in the segmented real-time current data, the current characteristic analysis is performed with the expected value of the corresponding segmented reference current in the reference current curve to obtain the current segmented characteristic parameter set. Based on the current segmentation characteristic parameter set, the jamming risk index, leakage risk index and local resistance anomaly index are calculated respectively. The blockage risk index, leakage risk index, and local resistance anomaly index are fused and scored according to preset comprehensive weights to generate a comprehensive pipeline health score. Based on the blockage risk index, leakage risk index, local resistance anomaly index, and pipeline comprehensive health score, the current status of the negative pressure transmission pipeline is determined as a blockage fault, leakage fault, local resistance anomaly, or healthy state, and encapsulated as a pipeline health diagnosis message to trigger the corresponding abnormal alarm.

10. A negative pressure pipeline material conveying control system, characterized in that, For performing the negative pressure pipeline material conveying control method as described in claim 1, the negative pressure pipeline material conveying control system includes: The heartbeat link maintenance module is used to establish a heartbeat detection strategy between the first-end host and the second-end host based on the RS485 communication bus. The peak-avoidance scheduling module is used to continuously monitor communication error events on the RS485 communication bus through a heartbeat detection strategy in order to extract electromagnetic interference characteristic data; and to construct a peak-avoidance adaptive transmission strategy based on the electromagnetic interference characteristic data. The session coordination control module is used to respond to the start button being pressed on the first host, triggering communication session locking and generating a transmission session identifier; the first host and the second host perform anti-interference timed interaction operations through peak avoidance adaptive transmission strategy and transmission session identifier, thereby realizing synchronous and coordinated management of operation permissions at both ends; The transmission session release module is used to release the transmission session identifier and unlock the communication session after detecting that the negative pressure material transmission is completed, so as to realize the control of negative pressure pipeline material transmission.

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